Method for Forming Three-Dimensional Patterns using Double Raschel Knitted Fabric

ABSTRACT

The present invention relates to a method for forming a three-dimensional pattern using a double Raschel knitted fabric, and more particularly, to a method for forming a three-dimensional pattern using a double Raschel knitted fabric, in which the facilitation of formation of visually aesthetic patterns can be ensured through a simple process during the surface-molding of the double Raschel knitted fabric having a feeling of volume and a cushion feeling, and in which the double Raschel knitted fabric can be given an adhesive property or a high abrasion resistance, or an adhesive property and a high abrasion resistance.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Korean Patent Application No.10-2017-0035567, filed on Mar. 21, 2017 in the Korean IntellectualProperty Office, which is incorporated herein by reference in itsentirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a method for forming athree-dimensional pattern using a double Raschel knitted fabric, inwhich the facilitation of formation of visually aesthetic patterns canbe ensured through a simple process during the surface-molding of thedouble Raschel knitted fabric having a feeling of volume and a cushionfeeling, and in which the double Raschel knitted fabric can be given anadhesive property or a high abrasion resistance, or an adhesive propertyand a high abrasion resistance.

2. Description of Related Art

In general, a double Raschel knitted fabric is a knitted fabric knittedby a typical double Raschel warp knitting machine through a knittingprocess, i.e., a warp knitting method in which a whole fabric texture isformed in a warp direction, i.e., in a vertical direction in theknitting process.

As a related art, Patent Document 1 discloses a method for manufacturinga double Raschel knitted fabric including an upper layer, a lower layer,and an intermediate layer that interconnects the upper and layer and thelower layer using a double Raschel warp knitting machine.

Specifically, the upper layer is knitted by allowing a plurality ofsurface yarn groups to form loops together with each other in such amanner that a first surface yarn group as any one of the surface yarngroups does not form loops together with the other surface yarn groupsfrom at constant floating sections to form transverse corrugations atpositions corresponding to the floating sections, that a tension of thefirst surface yarn group passing through the floating sections isgreater than that of the first surface yarn group passing through loopsections other than the floating sections, and that the speed of thefirst surface yarn group supplied to the floating sections is lower thanthat of the first surface yarn group supplied to the loop sections toadjust the tension of the first surface yarn group passing through thefloating sections.

However, such a conventional double Raschel knitted fabric entails aproblem in that the upper layer, the lower layer and the intermediatelayer are formed of only a typical fabric yarn (for example, mono yarn,polyester yarn, nylon yarn or cotton yarn), and as a result, a feelingof volume and a cushion feeling are implemented but an adhesive propertyor a high abrasion resistance or the facilitation of formation ofpatterns during the surface-molding of the double Raschel knitted fabricis not implemented.

In the meantime, the above conventional double Raschel knitted fabric isapplied to various kinds of mats or seats, and is typically manufacturedby bonding a cover fabric formed with a variety of patterns to the topsurface of the upper layer of the double Raschel knitted fabric by meansof an adhesive and sewing the cover fabric according to the shapes ofthe patterns formed on the cover fabric. However, a mat or seat to whichthe above conventional double Raschel knitted fabric is applied haveproblems in that a lower layer (i.e., a layer contacting with a bottomsurface) thereof is formed of only a typical fabric yarn (for example,mono yarn, polyester yarn, nylon yarn or cotton yarn), and as a result,a non-slip property of the mat or seat is very poor and thus the mat orseat easily slips on the bottom surface, thereby causing the occurrenceof various kinds of safety accidents or an inconvenience in use.

PRIOR ART LITERATURE Patent Documents

Patent Document 1: Korean Patent Registration No. 10-0987108 entitled“Method for Manufacturing Double Raschel Knitted Fabric formed withtransverse corrugations and Double Raschel Knitted Fabric Manufacturedthereby”

SUMMARY OF THE INVENTION

Accordingly, the present invention has been made to solve theaforementioned problems occurring in the prior art, and it is an objectof the present invention to provide a method for forming athree-dimensional pattern using a double Raschel knitted fabric, inwhich the facilitation of formation of visually aesthetic patterns canbe ensured through a simple process during the surface-molding of thedouble Raschel knitted fabric having a feeling of volume and a cushionfeeling, and in which the double Raschel knitted fabric can be given anadhesive property or a high abrasion resistance, or an adhesive propertyand a high abrasion resistance.

Specifically, another object of the present invention is to provide amethod for forming a three-dimensional pattern using a double Raschelknitted fabric, in which in the double Raschel knitted fabric composedof an upper layer, a lower layer, and an intermediate layer thatinterconnects the upper and layer L1 and the lower layer, the upperlayer L1 is formed of a TPU (Thermoplastic Polyurethane) yarn, the lowerlayer L2 is formed of a yarn coated with a hotmelt resin, and theintermediate layer is formed of a fabric yarn (jet spun yarn) so thatthe double Raschel knitted fabric can be given a feeling of volume and acushion feeling, and an adhesive property, as well as the facilitationof formation of patterns can be ensured during the surface-molding ofthe double Raschel knitted fabric and an abrasion resistance of thedouble Raschel knitted fabric can be improved.

Still another object of the present invention is to provide a method forforming a three-dimensional pattern using a double Raschel knittedfabric, in which in the double Raschel knitted fabric composed of anupper layer, a lower layer, and an intermediate layer that interconnectsthe upper and layer and the lower layer, the upper layer is formed of aTPU yarn, and the lower layer and the intermediate layer are formed of ageneral fabric yarn so that the double Raschel knitted fabric can begiven a feeling of volume and a cushion feeling, as well as thefacilitation of formation of patterns can be ensured during thesurface-molding of the double Raschel knitted fabric and an abrasionresistance of the double Raschel knitted fabric can be improved.

Yet another object of the present invention is to provide a method forforming a three-dimensional pattern using a double Raschel knittedfabric, in which in the double Raschel knitted fabric composed of anupper layer, a lower layer, and an intermediate layer that interconnectsthe upper and layer and the lower layer, the upper layer and theintermediate layer are formed of a general fabric yarn, and the lowerlayer is formed of a yarn coated with a hotmelt resin so that the doubleRaschel knitted fabric can be given a feeling of volume and a cushionfeeling, and an adhesive property, as well as the facilitation offormation of patterns can be ensured during the surface-molding of thedouble Raschel knitted fabric.

A further object of the present invention is to provide a method forforming a three-dimensional pattern using a double Raschel knittedfabric, in which in the double Raschel knitted fabric composed of anupper layer, a lower layer, and an intermediate layer that interconnectsthe upper and layer and the lower layer, the upper layer is formed of ayarn coated with a hotmelt resin, and the lower layer and theintermediate layer are formed of a general fabric yarn so that thedouble Raschel knitted fabric can be given a feeling of volume and acushion feeling, as well as the facilitation of formation of patternscan be ensured during the surface-molding of the double Raschel knittedfabric and an abrasion resistance of the double Raschel knitted fabriccan be improved.

A still further object of the present invention is to provide a methodfor forming a three-dimensional pattern using a double Raschel knittedfabric, in which in the double Raschel knitted fabric composed of anupper layer, a lower layer, and an intermediate layer that interconnectsthe upper and layer and the lower layer, the upper layer and the lowerlayer are formed of a yarn coated with a hotmelt resin, and theintermediate layer is formed of a general fabric yarn so that the doubleRaschel knitted fabric can be given a feeling of volume and a cushionfeeling, and an adhesive property, as well as the facilitation offormation of patterns can be ensured during the surface-molding of thedouble Raschel knitted fabric and an abrasion resistance of the doubleRaschel knitted fabric can be improved.

A yet further object of the present invention is to provide a method forforming a three-dimensional pattern using a double Raschel knittedfabric, in which in the double Raschel knitted fabric composed of anupper layer, a lower layer, and an intermediate layer that interconnectsthe upper and layer and the lower layer, the upper layer is formed of ayarn coated with a hotmelt resin, the lower layer is formed of a TPUyarn, and the intermediate layer is formed of a fabric yarn so that thedouble Raschel knitted fabric can be given a feeling of volume and acushion feeling, an adhesive property and an abrasion resistance, aswell as the facilitation of formation of patterns can be ensured duringthe surface-molding of the double Raschel knitted fabric, andformability and thus the aesthetic value of the exterior appearance ofthe double Raschel knitted fabric can be improved.

Another further object of the present invention is to provide a methodfor forming a three-dimensional pattern using a double Raschel knittedfabric, in which various kinds of mats or seats are manufactured byusing the double Raschel knitted fabric including a lower layer (i.e., alayer contacting with a bottom surface) formed of a yarn coated with ahotmelt resin or a TPU yarn so that the non-slip property of the mats orseats can be improved by the lower layer, thereby preventing a varietyof safety accidents and improving a convenience in use.

More specifically, another yet further object of the present inventionis to provide a method for forming a three-dimensional pattern using adouble Raschel knitted fabric, in which a cover fabric formed with avariety of patterns is bonded to the top surface of the upper layer ofthe double Raschel knitted fabric including a lower layer formed of ahotmelt resin-coated yarn or a TPU yarn by means of an adhesive and issewn according to the shapes of the patterns formed on the cover fabricto manufacture various kinds of mats or seats so that the non-slipproperty can be implemented and the adhesive strength of the coverfabric and the double Raschel knitted fabric can be implemented morestrongly and easily.

To achieve the above objects, the present invention provides a methodfor forming a three-dimensional pattern using a double Raschel knittedfabric composed of an upper layer L1, a lower layer L2, and anintermediate layer L3 that interconnects the upper and layer L1 and thelower layer L2, the method comprising surface-molding the double Raschelknitted fabric into the three-dimensional pattern by compressing thesurface of the double Raschel knitted fabric at a temperature of100-200° C. and a pressure of 10-70 kg/cm² for 10-60 seconds using amold formed with an engraved part so that a protruded part 20 a isformed at a portion of the double Raschel knitted fabric, whichcorresponds to the engraved part of the mold, and a compressed part 20 bis formed at the remaining portion other than the protruded part 20 a ofthe double Raschel knitted fabric to thereby form the three-dimensionalpattern.

Meanwhile, the upper layer L1 of the double Raschel knitted fabric maybe formed of a TPU fabric 22, the lower layer L2 may be formed of afabric 21 coated with a hotmelt resin, and the intermediate layer L3 maybe formed of a fabric yarn 23. The yarn 21 coated with a hotmelt resinmay be formed such that a hotmelt resin 21 d is coated on the outersurface of a fabric yarn 21 c consisting of a core 21 a and a sheath 21b in an amount of 0.03-0.3 g/m². The fabric yarn 21 c may be selectedfrom among a polyester yarn, a nylon yarn, and a cotton yarn, which areused alone or in combination of two or more thereof. The hotmelt resin21 d may be selected from among a polyester resin, a polyurethane resin,an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin,and a polyolefin resin, which are used alone or in combination of two ormore thereof.

In addition, the upper layer L1 and the intermediate layer L3 of thedouble Raschel knitted fabric may be formed of a fabric yarn 23, and thelower layer L2 thereof may be formed of a yarn 21 coated with a hotmeltresin. The yarn 21 coated with a hotmelt resin may be formed such that ahotmelt resin 21 d is coated on the outer surface of a fabric yarn 21 cconsisting of a core 21 a and a sheath 21 b in an amount of 0.03-0.3g/m². The fabric yarn 21 c may be selected from among a polyester yarn,a nylon yarn, and a cotton yarn, which are used alone or in combinationof two or more thereof. The hotmelt resin 21 d may be selected fromamong a polyester resin, a polyurethane resin, an acrylic resin, apolyimide resin, an ethylene vinyl acetate resin, and a polyolefinresin, which are used alone or in combination of two or more thereof.

In addition, the upper layer L1 of the double Raschel knitted fabric maybe formed of a yarn 21 coated with a hotmelt resin, and the lower layerL2 and the intermediate layer L3 thereof may be formed a fabric yarn 23.The yarn 21 coated with a hotmelt resin may be formed such that ahotmelt resin 21 d is coated on the outer surface of a fabric yarn 21 cconsisting of a core 21 a and a sheath 21 b in an amount of 0.03-0.3g/m². The fabric yarn 21 c may be selected from among a polyester yarn,a nylon yarn, and a cotton yarn, which are used alone or in combinationof two or more thereof. The hotmelt resin 21 d may be selected fromamong a polyester resin, a polyurethane resin, an acrylic resin, apolyimide resin, an ethylene vinyl acetate resin, and a polyolefinresin, which are used alone or in combination of two or more thereof.

In addition, the upper layer L1 and the lower layer L2 of the doubleRaschel knitted fabric may be formed of a yarn 21 coated with a hotmeltresin, and the intermediate layer L3 thereof may be formed a fabric yarn23. The yarn 21 coated with a hotmelt resin may be formed such that ahotmelt resin 21 d is coated on the outer surface of a fabric yarn 21 cconsisting of a core 21 a and a sheath 21 b in an amount of 0.03-0.3g/m². The fabric yarn 21 c may be selected from among a polyester yarn,a nylon yarn, and a cotton yarn, which are used alone or in combinationof two or more thereof. The hotmelt resin 21 d may be selected fromamong a polyester resin, a polyurethane resin, an acrylic resin, apolyimide resin, an ethylene vinyl acetate resin, and a polyolefinresin, which are used alone or in combination of two or more thereof.

In addition, the upper layer L1 of the double Raschel knitted fabric maybe formed of a yarn 21 coated with a hotmelt resin, the lower layer L2thereof may be formed of a TPU yarn 22, and the intermediate layer L3thereof may be formed a fabric yarn 23. The yarn 21 coated with ahotmelt resin may be formed such that a hotmelt resin 21 d is coated onthe outer surface of a fabric yarn 21 c consisting of a core 21 a and asheath 21 b in an amount of 0.03-0.3 g/m². The fabric yarn 21 c may beselected from among a polyester yarn, a nylon yarn, and a cotton yarn,which are used alone or in combination of two or more thereof. Thehotmelt resin 21 d may be selected from among a polyester resin, apolyurethane resin, an acrylic resin, a polyimide resin, an ethylenevinyl acetate resin, and a polyolefin resin, which are used alone or incombination of two or more thereof.

In the meantime, a cover fabric 200 may be laminated on the top surfaceof the upper layer L1 in such a manner that the cover fabric 200 and thetop surface of the upper layer L1 are boned to each other by means of ahotmelt film.

As described above, the present invention has an effect in that thefacilitation of formation of visually aesthetic patterns can be ensuredthrough a simple process during the surface-molding of the doubleRaschel knitted fabric having a feeling of volume and a cushion feeling,and in that the double Raschel knitted fabric can be given an adhesiveproperty or a high abrasion resistance, or an adhesive property and ahigh abrasion resistance.

In addition, the present invention has an effect in that a cover fabricformed with a variety of patterns is bonded to the top surface of theupper layer of the double Raschel knitted fabric including a lower layerformed of a hotmelt resin-coated yarn or a TPU yarn by means of anadhesive and is sewn according to the shapes of the patterns formed onthe cover fabric to manufacture various kinds of mats or seats so thatthe non-slip property can be implemented by the lower layer to preventvarious kinds of safety accidents and improve a convenience in use, andthe adhesive strength of the cover fabric and the double Raschel knittedfabric can be more strongly and easily implemented by the hotmelt film.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the presentinvention will be apparent from the following detailed description ofthe preferred embodiments of the invention when taken in conjunctionwith the accompanying drawings, in which:

FIG. 1 is a top plan view showing a state in which a three-dimensionalpattern is formed on the surface of a double Raschel knitted fabricaccording to a first embodiment of the present invention;

FIG. 2 is a cross-sectional view showing a structure of a double Raschelknitted fabric according to a first embodiment of the present invention;

FIG. 3 is a cross-sectional view showing a structure of a double Raschelknitted fabric according to a second embodiment of the presentinvention;

FIG. 4 is a cross-sectional view showing a structure of a double Raschelknitted fabric according to a third embodiment of the present invention;

FIG. 5 is a cross-sectional view showing a structure of a double Raschelknitted fabric according to a fourth embodiment of the presentinvention;

FIG. 6 is a cross-sectional view showing a structure of a double Raschelknitted fabric according to a fifth embodiment of the present invention;

FIG. 7 is a cross-sectional view showing a structure of a double Raschelknitted fabric according to a sixth embodiment of the present invention;

FIG. 8 is a cross-sectional view showing a structure of a yarn coatedwith a hotmelt resin applied to the present invention; and

FIGS. 9 and 10 are cross-sectional views showing a structure of a doubleRaschel knitted fabric on which a cover fabric is laminated according tothe present invention.

EXPLANATION ON SYMBOLS

20 a: protruded part

20 b: compressed part

L1: upper layer

L2: lower layer

L3: intermediate layer

21: yarn coated with a hotmelt resin yarn

21 a: core

21 b: sheath

21 c, 23: fabric yarn

21 d: hotmelt resin

22: TPU yarn

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention for achieving the above-mentioned effects isdirected to a method for forming a three-dimensional pattern using adouble Raschel knitted fabric. In the meantime, in the detaileddescription and the accompanying drawings, illustration and explanationon the construction and operation which a person skilled in the art caneasily understand will be briefly made or will be omitted to avoidredundancy. In particular, illustration and explanation on the detailedtechnical construction and operation of elements, which have no directconnection with the technical features of the present invention, will beomitted, and only the technical constructions directly related with thepresent invention will be briefly illustrated and explained.

Hereinafter, a method for forming a three-dimensional pattern using adouble Raschel knitted fabric according to the present invention will bedescribed in detail.

As shown in FIG. 1, the method for forming a three-dimensional patternusing a double Raschel knitted fabric according to the present inventionincludes surface-molding the double Raschel knitted fabric into thethree-dimensional pattern by compressing the surface of the doubleRaschel knitted fabric at a temperature of 100-200° C. and a pressure of10-70 kg/cm² for 10-60 seconds using a mold formed with an engraved part(at this time, the types of the mold and the engraved part may bemodified variously depending on designs) so that a protruded part 20 ais formed at a portion of the double Raschel knitted fabric, whichcorresponds to the engraved part of the mold, and a compressed part 20 bis formed at the remaining portion (i.e., a portion where the engravedpart of the mold is not formed) other than the protruded part 20 a ofthe double Raschel knitted fabric to thereby form the three-dimensionalpattern. Herein, if the surface-molding conditions are out of the aboverange, the three-dimensional pattern may not be formed properly.

In the meantime, in the double Raschel knitted fabric used in thepresent invention, which is composed of an upper layer L1, a lower layerL2, and an intermediate layer L3 that interconnects the upper and layerL1 and the lower layer L2 to give a feeling of volume and a cushionfeeling, a first embodiment, a fifth embodiment and a sixth embodimentmay be given an adhesive property (or tackiness) and a high abrasionresistance, a second embodiment and a fourth embodiment may be given ahigh abrasion resistance, and a third embodiment may be given anadhesive property.

Herein, the double Raschel knitted fabric is produced by a knittingprocess as described above. In other words, the double Raschel knittedfabric is a known knitted fabric knitted by a typical double Raschelwarp knitting machine, i.e., a warp knitting method in which a wholefabric texture is formed in a warp direction, i.e., in a verticaldirection in the knitting process. That is, the knitting type, methodand apparatus of the double Raschel knitted fabric have been known invarious manners, but are not particularly limited and any known knittingtype, method and apparatus of the double Raschel knitted fabric can beapplied to the present invention.

First, in the first embodiment of the present invention, as shown inFIG. 2, in the double Raschel knitted fabric used in the presentinvention, which is composed of an upper layer L1, a lower layer L2, andan intermediate layer L3 that interconnects the upper and layer L1 andthe lower layer L2 to give a feeling of volume and a cushion feeling,the upper layer L1 of the double Raschel knitted fabric is formed of aTPU yarn 22, the lower layer L2 thereof is formed of a yarn 21 coatedwith a hotmelt resin, and the intermediate layer L3 thereof is formed ofa fabric yarn (jet spun yarn) 23.

In other words, the yarn 21 coated with a hotmelt resin formed on thelower layer L2 gives an adhesive property to the double Raschel knittedfabric, the TPU yarn 22 formed on the upper layer L1 improves anabrasion resistance of the double Raschel knitted fabric, and theintermediate layer L3 formed of the fabric yarn 23 gives a feeling ofvolume and a cushion feeling to the double Raschel knitted fabric.

Further, the UPU yarn 22 formed on the upper layer L1 facilitates theformation of patterns during the surface-molding of the double Raschelknitted fabric.

In this case, the yarn 21 coated with a hotmelt resin serves to gives anadhesive property to the double Raschel knitted fabric, and as shown inFIG. 8, it is formed such that a hotmelt resin 21 d is coated on theouter surface of a fabric yarn 21 c consisting of a core 21 a and asheath 21 b in an amount of 0.03-0.3 g/m². If the coating content of thehotmelt resin 21 d is less than 0.03 g/m², the adhesive property may bedeteriorated, and if the coating content of the hotmelt resin 21 dexceeds 0.3 g/m², a defect may occur during the double Raschel knittingprocess due to an increase in the amount of the hotmelt resin 21 d.Meanwhile, the coating content of the hotmelt resin 21 d may vary in theextent being out of the above range depending on the kind or useenvironment of a product applied to the present invention.

In this case, examples of the fabric yarn 21 c included in the yarn 21coated with a hotmelt resin may include a polyester yarn, a nylon yarn,and a cotton yarn, which are used alone or in combination of two or morethereof, and examples of the hotmelt resin 21 d may include a polyesterresin, a polyurethane resin, an acrylic resin, a polyimide resin, anethylene vinyl acetate resin, and a polyolefin resin, which are usedalone or in combination of two or more thereof.

Herein, each of the examples of the hotmelt resin 21 d may be coated onthe fabric yarn 21 c irrespective of the kind of the fabric yarn 21 c,but the hotmelt resin 21 d and the fabric yarn 21 c may be selected inconsideration of the fusion property of the fabric yarn 21 c and thehotmelt resin 21 d through the coating process. In other words, if thepolyester yarn is selected as the fabric yarn 21 c, the polyurethaneresin is preferably coated as the hotmelt resin 21 d. If the nylon yarnis selected as the fabric yarn 21 c, the acrylic resin or the polyimideresin is preferably coated as the hotmelt resin 21 d. In addition, ifthe cotton yarn is selected as the fabric yarn 21 c, the ethylene vinylacetate resin or the polyolefin resin is preferably coated as thehotmelt resin 21 d.

In the meantime, the TPU yarn 22 refers to a yarn produced by extrudinga thermoplastic polyurethane (TPU) resin, which is a sort of yarn thatis already known in the art, and thus a detailed description thereofwill be omitted to avoid redundancy. Further, it is obvious to thoseskilled in the art that the TPU yarn 22 is formed of the above TPU resinso that it is relatively excellent in its abrasion resistance comparedto a general fabric yarn.

In addition, examples of the fabric yarn 23 used in the intermediatelayer L3 may include a polyester yarn, a nylon yarn, a mono yarn, and acotton yarn, which are used alone or in combination of two or morethereof.

In addition, in the second embodiment of the present invention, as shownin FIG. 3, in the double Raschel knitted fabric used in the presentinvention, which is composed of an upper layer L1, a lower layer L2, andan intermediate layer L3 that interconnects the upper and layer L1 andthe lower layer L2 to give a feeling of volume and a cushion feeling,the upper layer L1 is formed of a TPU yarn 22, and the lower layer L2and the intermediate layer L3 are formed of a fabric yarn 23.

In other words, the TPU yarn 22 formed on the upper layer L1 improves anabrasion resistance of the double Raschel knitted fabric, and theintermediate layer L3 formed of the fabric yarn 23 gives a feeling ofvolume and a cushion feeling to the double Raschel knitted fabric.

Further, the UPU yarn 22 formed on the upper layer L1 facilitates theformation of patterns during the surface-molding of the double Raschelknitted fabric.

In addition, in the third embodiment of the present invention, as shownin FIG. 4, in the double Raschel knitted fabric used in the presentinvention, which is composed of an upper layer L1, a lower layer L2, andan intermediate layer L3 that interconnects the upper and layer L1 andthe lower layer L2 to give a feeling of volume and a cushion feeling,the upper layer L1 and the intermediate layer L3 of the double Raschelknitted fabric are formed of a fabric yarn 23, and the lower layer L2thereof is formed of a yarn 21 coated with a hotmelt resin.

In other words, the yarn 21 coated with a hotmelt resin, formed on thelower layer L2 gives an adhesive property to the double Raschel knittedfabric, and the intermediate layer L3 formed of the fabric yarn 23 givesa feeling of volume and a cushion feeling to the double Raschel knittedfabric.

Further, in the fourth embodiment of the present invention, as shown inFIG. 5, in the double Raschel knitted fabric used in the presentinvention, which is composed of an upper layer L1, a lower layer L2, andan intermediate layer L3 that interconnects the upper and layer L1 andthe lower layer L2 to give a feeling of volume and a cushion feeling,the upper layer L1 of the double Raschel knitted fabric is formed of ayarn 21 coated with a hotmelt resin, and the lower layer L2 and theintermediate layer L3 thereof are formed a fabric yarn 23.

In other words, the hotmelt resin-coated yarn 21 formed on the upperlayer L1 improves an abrasion resistance of the double Raschel knittedfabric, and the intermediate layer L3 formed of the fabric yarn 23 givesa feeling of volume and a cushion feeling to the double Raschel knittedfabric.

Further, the hotmelt resin-coated yarn 21 formed on the upper layer L1facilitates the formation of patterns during the surface-molding of thedouble Raschel knitted fabric.

In addition, in the fifth embodiment of the present invention, as shownin FIG. 6, in the double Raschel knitted fabric used in the presentinvention, which is composed of an upper layer L1, a lower layer L2, andan intermediate layer L3 that interconnects the upper and layer L1 andthe lower layer L2 to give a feeling of volume and a cushion feeling,the upper layer L1 and the lower layer L2 of the double Raschel knittedfabric are formed of a yarn 21 coated with a hotmelt resin, and theintermediate layer L3 thereof is formed a fabric yarn 23.

In other words, the hotmelt resin-coated yarn 21 formed on the upperlayer L1 improves an abrasion resistance of the double Raschel knittedfabric, the yarn 21 coated with a hotmelt resin, formed on the lowerlayer L2 gives an adhesive property to the double Raschel knittedfabric, and the intermediate layer L3 formed of the fabric yarn 23 givesa feeling of volume and a cushion feeling to the double Raschel knittedfabric.

Further, the hotmelt resin-coated yarn 21 formed on the upper layer L1facilitates the formation of patterns during the surface-molding of thedouble Raschel knitted fabric.

In addition, in the sixth embodiment of the present invention, as shownin FIG. 7, in the double Raschel knitted fabric used in the presentinvention, which is composed of an upper layer L1, a lower layer L2, andan intermediate layer L3 that interconnects the upper and layer L1 andthe lower layer L2 to give a feeling of volume and a cushion feeling,the upper layer L1 of the double Raschel knitted fabric is formed of ayarn 21 coated with a hotmelt resin, the lower layer L2 thereof isformed of a TPU yarn 22, and the intermediate layer L3 thereof is formeda fabric yarn 23.

In other words, the hotmelt resin-coated yarn 21 formed on the upperlayer L1 improves an abrasion resistance of the double Raschel knittedfabric, and the intermediate layer L3 formed of the fabric yarn 23 givesa feeling of volume and a cushion feeling to the double Raschel knittedfabric.

Besides, in the sixth embodiment, the knitting structure of the TPU yarn22 is visibly observed from the outside of the upper layer L1 during theforming process due to a difference (typically, the melting point of theTPU yarn 22 is higher than that of the hotmelt resin-coated yarn 21) inthe melting point between the hotmelt resin-coated yarn 21 forming thelayer L1 and the TPU yarn 22 forming the lower layer L2 so thatformability and thus the aesthetic value of the exterior appearance ofthe double Raschel knitted fabric can be improved.

Further, the hotmelt resin-coated yarn 21 formed on the upper layer L1facilitates the formation of patterns during the surface-molding of thedouble Raschel knitted fabric.

In the meantime, the hotmelt resin-coated yarn 21, the TUP yarn 22 andthe fabric yarn 23, which are used in each of the above embodiments,have been described in the first embodiment, and thus the detaileddescription thereof will be omitted to avoid redundancy.

Further, in each of the above embodiments, in the case of the hotmeltresin-coated yarn 21 or the TPU yarn 22 forming the upper layer L1 orthe lower layer L2, the hotmelt resin-coated yarn 21, the TPU yarn 22and the fabric yarn 23 may be mixed to form each layer. Specifically,the hotmelt resin-coated yarn 21 may be mixed with the TPU yarn 22 orthe fabric yarn 23, and the TPU yarn 22 may be mixed with the hotmeltresin-coated yarn 21 or the fabric yarn 23, but are not limited theretoand various yarns or functional yarns may be mixed.

In other words, the double Raschel knitted fabric of the presentinvention is given an adhesive property and a high abrasion resistanceas in the first embodiment, the fifth embodiment and the sixthembodiment besides a feeling of volume and a cushion feeling, or isgiven an adhesive property as in the third embodiment. Alternatively, asin the sixth embodiment, formability and thus the aesthetic value of theexterior appearance of the double Raschel knitted fabric are improved sothat its use range and efficiency can be further extended.

Meanwhile, in the double Raschel knitted fabric having the abovestructure, as shown in FIGS. 9 and 10, in the case where a cover fabric200 is laminated on the top surface of the upper layer L1 of the doubleRaschel knitted fabric, the lower layer L2 (i.e., a layer contactingwith a bottom surface) is formed of the hotmelt resin-coated yarn 21 orthe TPU yarn 22 so that a non-slip property relative to the bottomsurface can be improved, and a variety of safety accidents can beprevented as well as a convenience in use can be enhanced in themanufacture of a mat or seat using the non-slip property.

In this case, in laminating the cover fabric 200 on the top surface ofthe upper layer L1 of the double Raschel knitted fabric, the coverfabric 200 and the top surface of the double Raschel knitted fabric areboned to each other by means of a general hotmelt film so that theadhesive property of the cover fabric 200 can be improved. Further, thedouble Raschel knitted fabric may be applied to various kinds of mats orseats by sewing according to the shape of a pattern formed on the coverfabric 200.

As described above, while the method for forming a three-dimensionalpattern using a double Raschel knitted fabric according to the presentinvention has been described and illustrated in connection with specificexemplary embodiments with reference to the accompanying drawings, itwill be readily appreciated by those skilled in the art that variousmodifications and changes can be made to the present invention withinthe technical spirit and scope of the present invention defined in theclaims.

What is claimed is:
 1. A method for forming a three-dimensional pattern using a double Raschel knitted fabric composed of an upper layer L1, a lower layer L2, and an intermediate layer L3 that interconnects the upper and layer L1 and the lower layer L2, the method comprising surface-molding the double Raschel knitted fabric into the three-dimensional pattern by compressing the surface of the double Raschel knitted fabric at a temperature of 100-200° C. and a pressure of 10-70 kg/cm² for 10-60 seconds using a mold formed with an engraved part so that a protruded part 20 a is formed at a portion of the double Raschel knitted fabric, which corresponds to the engraved part of the mold, and a compressed part 20 b is formed at the remaining portion other than the protruded part 20 a of the double Raschel knitted fabric to thereby form the three-dimensional pattern.
 2. The method according to claim 1, wherein the upper layer L1 of the double Raschel knitted fabric is formed of a TPU yarn 22, wherein the lower layer L2 thereof is formed of a yarn 21 coated with a hotmelt resin, wherein the intermediate layer L3 thereof is formed of a fabric yarn 23, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21 d is coated on the outer surface of a fabric yarn 21 c consisting of a core 21 a and a sheath 21 b in an amount of 0.03-0.3 g/m², wherein the fabric yarn 21 c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21 d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.
 3. The method according to claim 1, wherein the upper layer L1 and the intermediate layer L3 of the double Raschel knitted fabric are formed of a fabric yarn 23, wherein the lower layer L2 thereof is formed of a yarn 21 coated with a hotmelt resin, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21 d is coated on the outer surface of a fabric yarn 21 c consisting of a core 21 a and a sheath 21 b in an amount of 0.03-0.3 g/m², wherein the fabric yarn 21 c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21 d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.
 4. The method according to claim 1, wherein the upper layer L1 of the double Raschel knitted fabric is formed of a yarn 21 coated with a hotmelt resin, wherein the lower layer L2 and the intermediate layer L3 thereof are formed a fabric yarn 23, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21 d is coated on the outer surface of a fabric yarn 21 c consisting of a core 21 a and a sheath 21 b in an amount of 0.03-0.3 g/m², wherein the fabric yarn 21 c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21 d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.
 5. The method according to claim 1, wherein the upper layer L1 and the lower layer L2 of the double Raschel knitted fabric are formed of a yarn 21 coated with a hotmelt resin, wherein the intermediate layer L3 thereof is formed a fabric yarn 23, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21 d is coated on the outer surface of a fabric yarn 21 c consisting of a core 21 a and a sheath 21 b in an amount of 0.03-0.3 g/m², wherein the fabric yarn 21 c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21 d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof.
 6. The method according to claim 1, wherein the upper layer L1 of the double Raschel knitted fabric is formed of a yarn 21 coated with a hotmelt resin, wherein the lower layer L2 thereof is formed of a TPU yarn 22, wherein the intermediate layer L3 thereof is formed a fabric yarn 23, wherein the yarn 21 coated with a hotmelt resin is formed such that a hotmelt resin 21 d is coated on the outer surface of a fabric yarn 21 c consisting of a core 21 a and a sheath 21 b in an amount of 0.03-0.3 g/m², wherein the fabric yarn 21 c is selected from among a polyester yarn, a nylon yarn, and a cotton yarn, which are used alone or in combination of two or more thereof, and wherein the hotmelt resin 21 d is selected from among a polyester resin, a polyurethane resin, an acrylic resin, a polyimide resin, an ethylene vinyl acetate resin, and a polyolefin resin, which are used alone or in combination of two or more thereof. 